Download “G5” Stainless Steel Disc Brake Owners Manual

“G5”
Stainless Steel Disc
Brake Owners Manual
Stainless Steel Disc Brake Instructions
The advantages disc brakes have over drum brakes include:
• Greater fade resistance • Self-cleaning
• Self-adjusting • Less maintenance
• Greater stopping power • Easy visual inspection without removing any parts
Tie Down Engineering G5 Stainless Steel disc brakes with aluminum caliper have
many exclusive features not found on automotive type brakes modified for trailer use.
Please visit our web site www.tiedown.com for further information on features and benefits.
G5 Stainless Steel disc brakes are designed to activate when the vehicle’s brakes
are applied. As the vehicle stops or slows, the momentum of the trailer pushes
forward developing pressure in the actuator (master cylinder), used to apply pressure to
the brakes.
Operating Information
Read and understand the towing instructions for your tow vehicle, trailer and actuator.
Check your trailer frequently for any leaks in the hydraulic system, which includes the
actuator, brake lines and brakes.
If the trailer is used in salt water, it is highly recommended that you rinse off the
brakes with fresh water after each use to reduce the effects of saltwater corrosion and
salt build-up (residue).
Your trailer should tow easily. Disc brakes operate at a higher temperature than
drum brakes. This is normal and is very similar to the way disc brakes operate on your
vehicle. If for any reason your trailer does not tow easily or wants to veer to one side,
stop and investigate immediately and solve the problem.
Towing a trailer (even a trailer with brakes) puts an added load on the tow vehicle’s
handling and braking capabilities. Do not follow to closely; you will need extra distance
to maneuver and to stop.
Towing downhill puts added stress on both the tow vehicle and the trailer. Slow
down before you start on an incline and maintain a controlled downhill speed with
repeated application of brakes followed by a cooling period when brakes are not
applied. It is very important to start off with a slow speed and maintain it rather than
trying to slow down from a higher speed. Should you feel the brakes on the trailer or
tow vehicle are running hot or showing signs of fade, stop immediately on the side of
the road and allow the brakes to cool before resuming your trip.
Stainless Steel Disc Brake Instructions
Should you feel that the tow vehicle brakes or trailer brakes are not working
properly; have the tow vehicle and trailer brake system inspected. Make sure your
trailer’s GVWR is within the tow vehicles capacity. If your trailer has multiple axles,
verify that the GVWR of the trailer does not exceed the capacity of the brakes, which
is 3750 lbs on 10-inch (5 lug) brakes and 6000 lbs on 12-inch (6 lug) brakes, per axle.
Some states require brakes on all axles.
Check with your state laws and the state laws of where you will be using your trailer
prior to towing.
After long trips or downhill towing, your brakes could become very hot and it is a
good idea to let them cool down before submerging in cold water. The change in
temperature of very hot brakes submerged in water creates additional stress on the
parts and could cause damage to your brakes.
Pads must be replaced when the friction material is 3/32°± or less. Original Tie
Down Engineering brake pads for the G5 Stainless Steel disc brakes have a ceramic
pad material and a stainless steel backing plate that aids in corrosion resistance.
Disc brakes require the use of flexible brake lines attached to the caliper. The calipers
“float” and should not be used with metal brake lines that will restrict movement and
cause overheating or brake failure. If you are replacing existing brakes and using the
existing metal brake lines, either replace metal brake lines with a Tie Down Engineering
brake line kit or add flexible extensions to the metal lines to connect to the disc brake
calipers.
Disc brakes require the use of an actuator designed for disc brakes. If you are
replacing drum brakes, you must also change the actuator to a disc brake model. Using
a drum brake actuator with disc brakes will cause overheating, loss of braking power
and possible brake failure.
Use DOT 3 brake fluid only. DOT 3 can be labeled as “synthetic”.
DO NOT USE SILICONE BASED BRAKE FLUID.
When backing a trailer with disc brakes, you must have a lockout device on the
actuator or preferably an electrically operated solenoid to stop brake pressure to the
disc brakes. The solenoid is mounted at the rear of the actuator, between the master
cylinder and brake line. The solenoid has a wire that is connected to your back up
lights. When the tow vehicle transmission is put in reverse, the reverse light voltage
activates the solenoid. This will either stop or redirect the brake fluid to keep the brakes
from operating while in reverse.
2
“G5” Installation/Replacement Instructions for
9.6” 5-Lug Stainless Steel Disc Brakes
1.
2.
3.
4.
5.
Elevate the trailer on a level surface using the trailer manufacturer’s instructions. Always use jack stands for support. Do not depend on a jack to support the trailer. Block wheels to keep trailer from rolling.
If installation is on a completed trailer, remove tire/wheel.
Disc Brakes require the use of flexible brake lines attached to the caliper. The
calipers “float” and should not be used with metal brake lines that will restrict movement and cause overheating or brake failure. If you are replacing existing brakes and have metal brake lines, either replace the metal brake lines with a Tie Down Engineering flexible brake line kit or add flexible extensions to the metal lines to connect to the disc brake calipers.
Remove existing brakes or hubs. Clean spindles with a soft cloth to remove old grease and containments. Coat the spindle with a light coat of clean oil or grease to allow a smooth installation of the hub/rotor.
Place the G5 hub/rotor on the spindle. Install the washer and castle nut supplied with your axle, Rotate the hub while tightening the spindle nut to approximately
50 ft lbs. This translates into full hand pressure with a 12” long set of pliers or
12” long wrench.
Rotor/Hub
Rotor/Hub
Caliper
Caliper
Slider Pin
Slider Pin
Mounting
Mounting Bracket
Bracket
Install rotor/hub on spindle
Slide caliper onto the slider pins
Brake Li
6. Loosen the spindle nut to remove the torque, do not rotate hub.
7. Tighten the spindle nut until snug, backing out only to line up the lockingBrake
tang Line
washer Caliper
or cotter pin to the first available position.
Bolt &
8. Bend the locking tang tab or cotter pin in place.
Caliper
Nyloc Nut
9. Your G5 brakes come withMounting
pre-assembled mounting brackets and stainless
Bolt &steel Nyloc
Nut
slider pins. DO NOT REMOVE
SLIDER PINS. If the slider pins are removed
for any
Bracket
Mounting
reason the threads
must be cleaned and a new coat of “permanent” Loctite® Bracket
must be applied. Clean and apply Loctite® to threads on the mounting plate. Be Brake
careful not to get Loctite® on slider pins or bushings. Torque slider pins
Flange
to 40 ft. lbs
Brake
Bolt & Nyloc Nut
Flange
3
Brake
Bolt & Nyloc Nut
Slider Pin
Mounting
Bracket
Mounting
Bracket
Brake Line
Caliper
Caliper
Mounting
Bracket
Mounting
Bracket
Brake Line
Bolt &
Nyloc Nut
Bolt &
Nyloc Nut
Brake
Flange
Brake
Bolt & Nyloc Nut
Flange
Brake
Flange
Brake
Flange
Slide caliper/mounting bracket
over rotor
Bolt & Nyloc Nut
Bolt mounting bracket to the
brake flange
10. Slide the assembled caliper onto the slider pins. Attach the assembled mounting plate to the brake flanges on the axle, after sliding the caliper over the stainless steel rotor. Preferred positions are 12:00, 9:00 and 3:00 “o-clock” or to the
backside. The brake flange will determine the exact positioning. Use 7/16”x 1-1/4” zinc hex bolts, lock nuts/washers and torque to 40 ft. lbs.
11. Replace grease cap.
12. Caliper has a swivel inlet connector for the brake hose and a stainless steel bleeder valve. The bleeder valve should have the top or highest position on the caliper.
Position the swivel brake connector so that the brake line easily connects to the caliper. Tighten the bolt on the swivel connector to 20 ft. lbs.
13. Connect the flexible brake line to the swivel connector.
14. Repeat this assembly for the other wheels.
15. Install tire/wheel assembly(s), tighten wheel nuts to Trailer manufacturer or wheel manufacture’s specifications. Test wheel for excessive tightness or excessive play. Re-tension spindle nut if necessary.
16. Bleed brakes according to the trailer actuator’s instructions.
17. Road test vehicle in a safe place before traveling on main roads in traffic.
VERY IMPORTANT,
RE-CHECK LUG NUTS FOR PROPER TORQUE AFTER 25 MILES OF USE.
4
“G5” Installation/Replacement Instructions for
12” 6-Lug Stainless Steel Disc Brakes
1.
2.
3.
4.
Elevate the trailer on a level surface using the trailer manufacturer’s instructions. Always use jack stands for support. Do not depend on a jack to support the trailer. Block wheels to keep trailer from rolling.
If installation is on a completed trailer, remove tire/wheel.
Disc Brakes require the use of flexible brake lines attached to the caliper. The
calipers “float” and should not be used with metal brake lines that will restrict movement and cause overheating or brake failure. If you are replacing existing brakes and have metal brake lines, either replace the metal brake lines with a Tie Down Engineering flexible brake line kit or add flexible extensions to the metal lines to connect to the disc brake calipers.
Remove existing brakes or hubs. Clean spindles with a soft cloth to remove old grease and containments. Coat the spindle with a light coat of clean oil or grease to allow a smooth installation of the hub/rotor.
Rotor/Hub
Rotor/Hub
Mounting
Mounting
Bracket
Bracket
Brake
Brake
Flange
Flange
Bolts & Nyloc Nuts
Bolts & Nyloc Nuts
Bolt the mounting bracket to the
front of the brake flange
Install rotor/hub on spindle
Swivel Brake
Line Connector
Caliper
SwivelonBrake
5. Attach the mounting bracket to the front of the brake flanges
the axle.
Brake Line
Line
Connector
Caliper
Preferred positions are 12:00, 9:00 and 3:00 “o-clock” or
to the
backside. The brake flange will determine the exact positioning. Use 7/16”x 1-1/4” Brake Line
zinc hex bolts, lock nuts/washers and torque to 40 ft. lbs.
6. Place the G5 hub/rotor on the spindle. Install the washer and castle nut supplied
Pin
Slider
with your axle, Rotate the hub while tightening the spindle nut to approximately
50 ft lbs. This translates into full hand pressure with a 12” long set of pliers orSlider Pin
12” long wrench.
7. Loosen the spindle nut to remove the torque, do not rotate hub.
8. Tighten the spindle nut until snug, backing out only to line up the locking tang washer or cotter pin to the first available position.
9. Bend the locking tang tab or set cotter pin in place.
10. Replace dust/grease cap.
5
Bolts & Nyloc
Bolts
Nuts
& Nyloc Nuts
Caliper
Caliper
Swivel Brake
Swivel Brake
Line Connector
Line Connector
Brake Line Brake
Slider Pin Slider P
Slide the caliper over the
mounting bracket and rotor
Install and tighten the slider pins
to 40 ft. lbs. Attach brake lines
11. Slide the G5 caliper over the rotor and between both brake pads
12. Install slider pins. Clean and apply Loctite® to threads on the mounting plate. Be
careful not to get Loctite® on slider pins or bushings. Torque slider pins to 40 ft. lbs. NOTE: The slider pins come pre-coated with Loctite®. If the slider pins are installed then REMOVED for any reason the threads must be cleaned and a new coat of “permanent” Loctite® must be applied.
13. Caliper has a swivel inlet connector for the brake hose and a stainless steel bleeder valve. The bleeder valve should have the top or highest position on the caliper.
Position the swivel brake connector so that the brake line easily connects to the caliper. Tighten the bolt on the swivel connector to 20 ft. lbs.
14. Connect the flexible brake line to the swivel connector.
15. Repeat this assembly for the other wheels.
16. Install tire/wheel assembly(s), tighten wheel nuts to Trailer manufacturer or wheel manufacture’s specifications. Test wheel for excessive tightness or excessive play. Re-tension spindle nut if necessary.
17. Bleed brakes according to the trailer actuator’s instructions.
18. Road test vehicle in a safe place before traveling on main roads in traffic.
VERY IMPORTANT,
RE-CHECK LUG NUTS FOR PROPER TORQUE AFTER 25 MILES OF USE.
6
Swivel Brake Line Connector
Caliper
Slider Pin
9.6”
Mounting
Bracket
G5 Stainless
Steel Disc
Brake
Assembly
Spindle
Nut/Bolt
Intergal Style Rotor
Brake
Flange
Stainless
Steel
Rotor
Swivel Brake
Line Connector
Caliper
Slider Pin
Mounting
Bracket
12”
G5 Stainless
Steel Disc
Brake
Assembly
Intergal Style Rotor
7
Nut/Bolt
Stainless
Steel
Rotor
Brake
Flange
Replacing Brake Pads
1. Elevate the trailer on a level surface using the trailer manufacturer’s instructions. Always use jack stands for support. Do not depend on a jack to support the trailer. Block wheels to keep trailer from rolling.
2. Remove the tire/wheel assembly. Inspect the rotor surface. Check for excessive
wear or grooves that may affect braking. Original rotor thickness is .313 in.;
minimum thickness is .25 in.
3. Inspect brake pads. Minimum thickness is 3/32°±. Pads should be replaced if less then minimum thickness.
9.6” G5 Brake Pad Replacement
4. Remove the caliper by first removing the four mounting bolts from the mounting bracket and brake flange. Lift the mounting bracket and caliper assembly off of the rotor. Be careful to hold the caliper in place so that it does not fall and pull on the
brake hose The inside pad is spring loaded in the caliper piston. Pry this pad out gently with a flat blade screwdriver. The outside pad is held in place with a center mounted spring tab. After removing the inside pad, the outside pad can be pulled from the caliper.
5. Clean the rotor with a brake cleaning spray. Replace brake pads in the reverse order. For ease of assembly, make sure the piston in the caliper is fully depressed into the caliper.
6. Re-attach the mounting bracket to the axle brake flange, sliding the caliper over the rotor. Tighten the four mounting bracket bolts. Torque bolts to 40 lbs.
7. Should you remove the slider pins for any reason, clean the threads on the slider bolt and mounting plate and apply a coating of Loctite or similar brand of thread lock. Tighten slider pins to 40 ft lbs. DO NOT REASSEMBLE WITHOUT APPLYING LOCTITE® TO THE SLIDER PIN THREADS AND THE BACKING PLATE. SLIDER PINS WITH OUT LOCKTITE® APPLIED COULD BACK OUT AND CAUSE
PERMANENT DAMAGE TO YOUR BRAKES AND TRAILER.
12” G5 Brake Pad Replacement
4. Remove the caliper by first removing the two slider pins from the mounting
bracket. Be careful to hold the caliper in place so that it does not fall and pull
on the brake hose. The inside pad is spring loaded in the caliper piston. Pry this
pad out gently with a flat blade screwdriver. The outside pad is held in place with
a center mounted spring tab. After removing the inside pad, the outside pad can be pulled from the caliper.
5. Clean the rotor with a brake cleaning spray. Replace brake pads in the reverse
order. For ease of assembly, make sure the piston in the caliper is fully depressed into the caliper.
6. Re-attach the caliper to the mounting bracket, sliding the caliper over the rotor. Before installing the slider pins, the threads must be cleaned and a new coat
of “permanent” Loctite® must be applied. Clean and apply Loctite® to threads on the mounting plate. Be careful not to get Loctite® on slider pins or bushings. Torque slider pins to 40 ft. lbs.
8
9.6” Stainless Steel Disc Brake Kit
#
1
2
3
4
Parts
9.6” Stainless Steel Rotor w/GalvX Hub
Caliper Assembly
Ceramic/Stainless Steel Brake Pads
Adjustable Banjo Assembly
4A
Brass Banjo Fitting
4B
Stainless Steel Banjo Bolt
4C
Copper Crush Washer (2)
Stainless Steel Bleed Valve(1)
Stainless Steel Slider Pins (2)
Mounting Bracket
Dust Cap
Cotter Pin 1/8" x 1-3/4" Zinc
Castle Nut - 6 position
Castle Nut - 12 position
Washer - Flat Spindle 1"
Outer Bearing (Cone) 1-1/16" (L44649)
Outer Cup (Race) 1-1/16" (L44610)
Studs 1/2"- 20 x 2.0" OAL
Inner Cup (Race) 1-3/8" (L68111)
Inner Bearing (Cone) 1-3/8" (L68149)
Oil Seal - Triple Lip 1.719" (171255UC)
5
6
7
8
9
10
10
11
12
13
14
15
16
17
Part #
46911X
46910A
11351/11350
11341
11337
11338
11339
11246SS
12114
44687X
17094
10551
10665
10634
10520
11054
11055
11123
11061
11060
11088
Replacement Kits:
Ceramic Brake Pad Kit (Consumer Aftermarket)
Ceramic Brake Pad Kit (OEM)
Caliper Rebuild Kit
4(A, B & C)
81252
81114
46304RB
6
2
7
5
1
3
8
9
10 11 12
13
14
9
15 16
17
12” Stainless Steel Disc Brake Kit
#
1
2
3
4
Parts
12” Stainless Steel Rotor w/GalvX Hub
Caliper Assembly
Ceramic/Stainless Steel Brake Pads
Adapter Port Assembly
4A
Brass Banjo Fitting
4B
Stainless Steel Banjo Bolt
4C
Copper Crush Washer (2)
Stainless Steel Bleed Valve (1)
Stainless Steel Slider Pins (2)
Mounting Bracket
Dust Cap
Cotter Pin 1/8" x 1-3/4" Zinc
Castle Nut - 6 position
Castle Nut - 12 position
Washer - Flat Spindle 1"
Outer Bearing (Cone) 1-1/4" (L15123)
Outer Cup (Race) 1-1/4" (L15245)
Stud 1/2" - 20 x 2.5" OAL (6)
Inner Cup (Race) 1-3/4" (L25520)
Inner Bearing (Cone) 1-3/4" (L25580)
Oil Seal - Triple Lip 2.25" (225255UC)
5
6
7
8
9
10
10
11
12
13
14
15
16
17
Part #
46912X
46910A
11351/11350
11341
11337
11338
11339
11246SS
12114
44688X
46494
10551
10665
10634
10520
11056
11066
11133
11067
11064
11086
Replacement Kits:
Ceramic Brake Pad Kit (Consumer Aftermarket)
Ceramic Brake Pad Kit (OEM)
Caliper Rebuild Kit
81252
81114
46304RB
6
7
4(A, B & C)
2
5
1
3
8
9
10 11
12
13
14
15
16
17
10
G5 Stainless Steel Disc
Brake Owners Manual
For up to date instructions visit the
“Marine Downloads” section at:
TIE DOWN ENGINEERING
255 Villanova Drive SW, Atlanta, GA 30336
(404) 344-0000 • Fax (404) 349-0401
© 2011 TIE DOWN ENGINEERING, ALL RIGHTS RESERVED
Instruction Manual #08134
042911,C1154
www.tiedown.com